Method of producing perforated retroreflective trim

ABSTRACT

A method for producing a perforated retroreflective trim that includes the steps of providing a substrate having first and second sides and a plurality of openings extending between the sides, providing a backing on the first side of the substrate, providing a retroreflective layer on the second side of the substrate, adhering the retroreflective layer to the second side of the substrate and to the backing within the openings of the substrate so that portions of the retroreflective layer are adhered to the backing through the openings in the substrate, and removing the backing from the first side of the substrate to strip away from the retroreflective layer the portions of the retroreflective layer adhered to the backing through the openings in the substrate to provide the perforated retroreflective trim.

FIELD OF THE INVENTION

The present invention relates to perforated retroreflective trim,perforated retroreflective fabric and perforated retroreflective tapeand to a method for producing a perforated retroreflective trim, fabricor tape. For the sake of convenience, the term perforatedretroreflective trim is used in the foregoing discussion of theinvention, however, it is to be appreciated that the reference toperforated retroreflective trim includes perforated retroreflectivefabric or perforated retroreflective tape and may also be a reference toother perforated flexible retroreflective materials, that would benefitfrom incorporating the principles of the invention.

BACKGROUND OF THE INVENTION

Retroreflective trim is often used in or provided on the outer layer ofgarments such as fire fighter garments, construction worker garments,road and rail worker garments and jogging suits. Such garments may bereferred to as high visibility safety garments. The reason for providingthe retroreflective trim is to reflect available light in darkenvironments so as to enhance the visibility of the garment to which thetrim is applied as well as the wearer of the garment.

In some circumstances law mandates that individuals must wear highvisibility garments incorporating retroreflective trim material whenengaged in certain activities in adverse light conditions or even inlight conditions that are not adverse. Such laws often require highvisibility safety garments be worn by people in situations where theymay be exposed to hazards from moving plant or equipment, motorvehicles, trains etc.

National and international standards are applicable to retroreflectivetrim used in relation to the aforementioned garments. Such standardsspecify various minimum requirements for high visibility safety garmentsand for trim material used in relation to such garments. For example,retroreflective trim applied used in relation to high visibilitygarments or other objects may be required to meet minimum thresholdrequirements for visibility, retroreflectivity and other physicalperformance properties such as abrasion resistance and wear resistance.

The stringent requirements of the standards applicable toretroreflective trim have meant that existing retroreflective trim isformed as a continuous non-permeable, non-perforated sheet which is notbreathable. A problem with existing retroreflective trim is that it doesnot easily permit the transfer of heat or vapour from perspirationemanating from the wearer of a garment incorporating the retroreflectivetrim. Accordingly, the wearer of the garment is subjected to a build upof heat and vapour within the garment resulting in stress to the wearer.This problem is significant given that while wearing high visibilityretroreflective garments the wearers are frequently engaged in strenuousphysical activity or are subjected to warm environments.

Another crucial requirement of retroreflective trim is that theretroreflective component, which is usually a retroreflective coatingapplied to a substrate, must be strongly bound to the underlyingsubstrate. This is so that the retroreflective trim can meet standardsrequiring the retroreflective component to be resistant to abrasionresulting from when a garment incorporating the retroreflective trim isworn or washed and from general wear and tear. In fact, this property ofthe retroreflective trim is crucial to its ability to meet standardsapplicable to such materials. This is because although a retroreflectivetrim may initially meet the retroreflectivity requirements after anumber of wash cycles the adherence of the retroreflective component tothe substrate may degrade to the extent that the retroreflectivecomponent may separate from the substrate such that the retroreflectivetrim no longer meets the minimum threshold standards forretroreflectivity.

Previous attempts to provide a breathable retroreflective trim haveinvolved perforating continuous non porous retroreflective trim withperforating needles. However, the perforated retroreflective trimresulting from this process may be insufficient to meet the standardsfor retroreflective trim such as retroreflectivity, abrasion resistanceand wear resistance. The perforated retroreflective trim when used withhigh visibility garments may not provide adequate breathability and maybe ineffective for allowing or enhancing the transport of heat and watervapour emanating from the wearer from within the garment to the externalenvironment outside the garment and ineffective for enhancing thecomfort of the wearer. Further, the perforated retroreflective trim maynot result in the retroreflective component or coating being stronglybound to the underlying substrate. Perforated trim resulting from usingperforating needles may also have poor appearance and qualitycharacteristics and may be relatively inefficient to manufacture.

The above discussion of acts, materials, devices, articles and the likeis included in this specification solely for the purpose of providing acontext for the present invention. It is not suggested or representedthat any of these matters are known, form part of the prior art base orare common general knowledge in the field relevant to the presentinvention at the priority date of each claim of this application.

Accordingly, there is a need for a breathable retroreflective trim foruse with high visibility garments that is sufficient to meet thestandards for retroreflective trim such as retroreflectivity and otherphysical performance properties such as abrasion resistance and wearresistance. There is also a need for a breathable retroreflective trimin which the retroreflective component or coating is strongly bound tothe underlying substrate. Furthermore, there is a need for a breathableretroreflective trim that is efficient to produce and that has superiorappearance and quality characteristics. There is yet furthermore a needfor a method of producing such breathable retroreflective trims.

SUMMARY OF THE INVENTION

Accordingly, in a first aspect the present invention provides a methodfor producing a perforated retroreflective trim that includes the stepsof:

providing a substrate having first and second sides and a plurality ofopenings extending between the sides;

adhering a continuous retroreflective layer to the second side of thesubstrate; and

removing portions of the retroreflective layer located within theopenings of the substrate to provide the perforated retroreflectivetrim.

Preferably, the method further includes the step of providing a backingon the first side of the substrate before the step of adhering thecontinuous retroreflective layer to the second side of the substratesuch that the retroreflective layer adheres to the second side of thesubstrate and to the backing within the openings of the substrate sothat portions of the retroreflective layer are adhered to the backingthrough the openings in the substrate. More preferably, the step ofremoving portions of the retroreflective layer located within theopenings of the substrate includes removing the backing from the firstside of the substrate to remove from the retroreflective layer theportions of the retroreflective layer adhered to the backing through theopenings in the substrate.

In another aspect, the present invention provides a method for producinga perforated retroreflective trim that includes the steps of:

providing a substrate having first and second sides and a plurality ofopenings extending between the sides;

providing a backing on the first side of the substrate;

providing a retroreflective layer on the second side of the substrate;adhering the retroreflective layer to the second side of the substrateand to the backing within the openings of the substrate so that portionsof the retroreflective layer are adhered to the backing through theopenings in the substrate; and

removing the backing from the substrate to strip away from theretroreflective layer the portions of the retroreflective layer adheredto the backing within the openings of the substrate to provide theperforated retroreflective trim.

In another aspect, the invention also provides a perforatedretroreflective trim produced by the method of the invention. In yetanother aspect, the present invention provides a garment incorporatingperforated retroreflective trim produced by the method of the invention.

The present invention is advantageous in that it may provide aperforated retroreflective trim that is porous, breathable and suitablefor use with high visibility garments for allowing or enhancing thetransport of heat and water vapour emanating from the wearer from withinthe garment to the external environment outside the garment so as toenhance the comfort of the wearer. Another advantage of the method ofthe invention is that existing materials and equipment may be used inthe method to produce a perforated retroreflective trim exhibiting theaforementioned properties. Given that existing components and equipmentmay be used with the present method the method is cost effective, andeconomical.

In addition, the invention has resulted in the surprising discovery thatthe perforated retroreflective trim produced in accordance with theinvention may exhibit improvements over perforated retroreflectivematerial produced by existing methods. In particular, the presentinvention may exhibit improvements in retroreflectivity, abrasionresistance and wear resistance as well as strong binding of theretroreflective layer to the substrate despite the fact that there areopenings in the substrate. Furthermore, the invention may result in aperforated retroreflective trim having superior appearance and qualitycharacteristics.

Furthermore, the present invention may enable perforated retroreflectivetrim to be produced that when incorporated into high visibilitygarments, provides such high visibility garments with an enhancedability to meet standards applicable thereto.

Preferably, in the method, the step of providing a retroreflective layeron the second side of the substrate includes providing a retroreflectivelayer which is a retroreflective heat transfer film.

In a particularly preferred embodiment the step of adhering theretroreflective layer includes heat laminating the retroreflective layerto the substrate and to the backing sheet within the openings of thesubstrate. This embodiment is particularly advantageous in that existingheat laminating equipment may be used so as to provide a method inaccordance with the invention that is cost efficient and economical toadopt. Furthermore, the heat laminated retroreflective layer of thisembodiment strongly adheres to the second side of the substrate and tothe backing sheet within the openings of the substrate. Accordingly,after the step of removing the backing the heat laminatedretroreflective layer strongly adheres to the second side of thesubstrate, particularly around the edges of the openings in thesubstrate, thus resulting in a perforated retroreflective trim with theenhanced characteristics of the invention outlined above as well asother benefits that will be evident upon employing the method of theinvention.

Preferably, the steps of providing the substrate, the backing andretroreflective layer includes providing the substrate, the backing andretroreflective layer continuously. In another preferred form, the stepof adhering the retroreflective layer preferably includes continuouslyadhering the retroreflective layer to the second side of the substrateand to the backing within the openings of the substrate so that portionsof the retroreflective layer are continuously adhered to the backingthrough the openings in the substrate. In yet another preferred form,the step of removing the backing from the first side of the substrateincludes continuously removing the backing from the first side of thesubstrate to continuously strip away from the retroreflective layer theportions of the retroreflective layer adhered to the backing through theopenings in the substrate to continuously provide the perforatedretroreflective trim.

Preferably, the method of the present invention includes providing asubstrate which is a polyester mesh. In other embodiments the method ofthe present invention includes providing a backing which may be abacking sheet. The backing may be coated paper, pvc or other man madefabrics or flexible materials. Preferably, the backing sheet iscontacted with the first side of the substrate. In yet anotherembodiment, the step of adhering the retroreflective layer includes heatlaminating retroreflective heat transfer film.

In one form, the step of adhering the retroreflective layer includesfeeding the substrate, backing and retroreflective layer into a heatpress set at a predetermined temperature, for a predetermined time. Inanother form, the step of adhering the retroreflective layer includesfeeding the substrate, backing and retroreflective layer into a heatlaminating machine set at a predetermined temperature, for apredetermined time. Preferably, the temperature is 110° C. and theperiod of time is 15 seconds. Preferably, the method further includescooling the retroreflective layer before the step of removing thebacking.

In another form, the step of removing the backing includes peeling awaythe backing from the first side of the substrate such that the portionsof the retroreflective layer adhered to the backing through the openingsof the substrate are thereby pulled out from within the openings tostrip away the portions of the retroreflective layer adhered to thebacking from the retroreflective layer to provide the perforatedretroreflective trim. After removal, the backing is provided with aseries of portions of the retroreflective layer heat laminated theretothat substantially correspond with the openings of the substrate.

In another form, the method further includes heating or cooking theretroreflective layer after the step of removing the backing.Preferably, the retroreflective layer and substrate are heated or cookedin a heat press set to a predetermined temperature and for apredetermined time. Preferably, the temperature is 160° C. and theperiod of time is 25 seconds.

In one form, the present invention provides a strip of perforatedflexible retroreflective material produced by the above method. It is tobe appreciated, however, that the method of the invention may be used toproduce a range of flexible retroreflective materials that, preferably,are able to be incorporated into high visibility garments. In apreferred form, the retroreflective material or trim produced by theabove method may be washable.

Preferably, the perforated retroreflective trim meets visibilitystandards of AS/NZS 1906.4.

The present invention will now be described in more detail withreference to the following preferred embodiments. However, it is to beappreciated that the present invention is not limited the embodimentsdescribed in the foregoing as other methods and products incorporatingthe principles of the invention outlined above may fall within the scopeof the invention also.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further explained with reference to thedrawings, wherein:

FIG. 1 is an exploded perspective view of the substrate having first andsecond sides and openings between the sides as well as the backing andthe retroreflective layer used in the method of the invention.

FIG. 2 is a perspective view of the substrate, backing andretroreflective layer of FIG. 1 with the substrate sandwiched betweenthe backing and the retroreflective layer.

FIG. 3 is a perspective view of the substrate, backing andretroreflective layer of FIG. 1 with the backing being removed to stripaway from the retroreflective layer the portions of the retroreflectivelayer adhered to the backing.

FIG. 4 is a perspective view of perforated trim formed from the methodof the invention, the perforated trim including the substrate andretroreflective layer of FIG. 1 with the portions of the retroreflectivelayer adhered to the backing stripped away from the retroreflectivelayer.

FIG. 5 is a perspective view of the backing of FIG. 1 with the portionsof the retroreflective layer adhered to the backing that have beenstripped away from the retroreflective layer.

FIG. 6 is a plan view of perforated retroreflective trim formed from themethod of the invention, the perforated retroreflective trim includingthe substrate and retroreflective layer of FIG. 1.

FIG. 7 is a side view of view of the substrate, backing andretroreflective layer of FIG. 1 being fed from rolls of the substrate,backing and retroreflective layer onto a guide where the substrate issandwiched between the backing and the retroreflective layer and theninto a laminating machine in accordance with a preferred form of themethod of the invention.

FIG. 8 is a side view of view of the perforated retroreflective trim ofFIG. 4 and the backing of FIG. 5 being fed onto rolls after exiting fromthe laminating machine of FIG. 7 in accordance with a preferred form ofthe method of the invention.

Referring to FIGS. 4 and 6 there is shown a perforated retroreflectivetrim 20 produced by the method of the present invention. The perforatedtrim 20 includes a substrate 30 and a retroreflective layer 40 and holes25 through the perforated trim 20 which provide the perforated trim 20with the characteristic of being perforated.

FIGS. 1 to 5 particularly illustrate the method of the invention. Asparticularly illustrated in FIGS. 1 and 2 the method includes providingthe substrate 30 which has a first side 35 and a second side 37 andopenings 39 between the sides 35, 37. Subsequently, on the first side 35of the substrate 30 a backing 50 is provided while on the second side 37of the substrate 30 a continuous retroreflective layer 40 is provided.With the backing 50 applied to the first side 35 of the substrate 30 asurface 55 of the backing 50 facing the second side 37 of the substrate30 is accessible from the second side 37 of the substrate 30 through theopenings 39 in the substrate 30. The effect of the steps in the methoddetailed thus far is that the substrate 30 is sandwiched between thebacking 50 and the continuous retroreflective layer 40.

Furthermore, in the method the continuous retroreflective layer 40 canbe, and is, adhered to the second side 37 of the substrate 30 as well asto the surface 55 of the backing 50 that is accessible from the secondside 37 of the substrate 30 within the openings 39 of the substrate 30.As a result of this step in the method, portions 45 of the continuousretroreflective layer 40 are adhered to the surface 55 of the backing 50through the openings 39 of the substrate 30. The portions 45 of theretroreflective layer 40 are illustrated in FIG. 5 as adhered to thebacking 50 after the subsequent step in the method, which isparticularly illustrated in FIG. 3, of removing the backing 50 from thefirst side 35 of the substrate 30 to strip away from the retroreflectivelayer 40 the portions 45 of the retroreflective layer 40 adhered to thesurface 55 of the backing 50 through the openings 39 of the substrate30. This final step of the method results in providing the perforatedretroreflective trim 20 illustrated in perspective view in FIG. 4 and inplan view in FIG. 6.

In a particularly preferred embodiment of the method of the inventionthe step of providing the retroreflective layer 40 on the second side 37of the substrate 30 includes providing a retroreflective layer 40 whichis a retroreflective heat transfer film. In an alternate embodiment thestep of providing the retroreflective layer 40 on the second side 37 ofthe substrate 30 includes providing a retroreflective layer 40 which isa retroreflective film or other flexible retroreflective material.

In embodiments of the invention where the retroreflective layer 40 is aretroreflective heat transfer film the step of adhering theretroreflective layer 40 to the second side 37 of the substrate 30 andto the backing 50 within the openings 39 of the substrate 30 includesheat laminating the retroreflective layer 40 to the second side 37 ofthe substrate 30 and to the backing 50 within the openings 39 of thesubstrate 30 so that portions 45 of the retroreflective layer 40 areadhered to the backing 50 through the openings 39 of the substrate 30.Such forms of the method are particularly advantageous in that existingheat laminating equipment may be utilised in the method rendering themethod cost efficient and economical to adopt. Furthermore, the heatlaminated retroreflective layer 40 of this embodiment strongly adheresto the second side 37 of the substrate 30 and to the surface 55 of thebacking sheet 50 within the openings 39 of the substrate 30.

Accordingly, after the step of removing the backing 50 the heatlaminated retroreflective layer 30 strongly adheres to the second side37 of the substrate 30, particularly around the edges of the openings 39in the substrate 30. This results in providing a perforatedretroreflective trim 20 that may exhibit enhanced characteristicsincluding improvements in retroreflectivity and/or wear resistanceand/or abrasion resistance and/or strong binding of the retroreflectivelayer 30 to the substrate 30. Furthermore, the method of the inventionmay result in a perforated retroreflective trim having superiorappearance and quality characteristics. Furthermore, the method of theinvention may enable perforated retroreflective trim 20 to be producedthat when incorporated into high visibility garments, provides such highvisibility garments with an enhanced ability to meet standardsapplicable thereto. Furthermore, the method of the invention may enableperforated retroreflective trim 20 to be produced that is porous,breathable and suitable for use with high visibility garments forallowing or enhancing the transport of heat and water vapour emanatingfrom the wearer from within the garment to the external environmentoutside the garment so as to enhance the comfort of the wearer.

Preferably, the substrate 30 used in the invention is a polyester meshthat has a plurality of rows and columns of openings 39 passing throughthe mesh between the first side 35 and second side 37 of the mesh. Whilea polyester mesh, such as a woven polyester mesh, is preferred, otherman made or natural substantially flexible materials may be equallyapplicable in the invention as the substrate 30 as long as the substrate30 that is adopted has a plurality of openings 39 therethrough and isadapted to the purpose of the invention.

The backing 50 used in the method of the invention may be coated paper,pvc or other man made fabrics or flexible materials that are suited tothe purpose ascribed for the backing 50 in the method. Accordingly, thebacking 50 may be any material suited for: being provided to the firstside 35 of the substrate 30; adherence by the retroreflective layer 40within the openings 39 of the substrate 30 so that portions 45 of theretroreflective layer 40 are adhered to the backing 50 within theopenings 39 of the substrate 30; and being removed from the first side35 of the substrate 30 to strip away from the retroreflective layer 40the portions 45 of the retroreflective layer 40 adhered to the backing50 within the openings 39 of the substrate 30.

FIG. 7 illustrates a preferred means of carrying out at least part ofthe method of the invention in which the substrate 30, the backing 50and the retroreflective layer 40 are respectively fed from a roll 140 ofthe substrate 30, a roll 120 of the backing 50 and a roll 130 of theretroreflective layer 40 into a laminating machine 110. The laminatingmachine 110 includes a guide 115 onto which the substrate 30 issandwiched between the backing 50 and the retroreflective layer 40before the sandwiched substrate 30, backing 50 and retroreflective layer40 are fed into the laminating machine 110. The laminating machine 110,may be a heat laminating machine that is suited for heat laminating theretroreflective layer 40 to adhere it to the substrate 30 and to thesurface 55 of the backing 50 within the openings 39 of the substrate 30when the retroreflective layer 40 used in the method is aretroreflective heat transfer film. An alternative to using a heatlaminating machine 110 in the method is to feed the substrate 30, thebacking 50 and the retroreflective layer 40 into a heat press (notshown). In each case, both the heat laminating machine 110 and the heatpress include a heat laminating element (not shown) that is set at apredetermined temperature such that after it is engaged for apredetermined time by the sandwiched substrate 30, backing 50 andretroreflective layer 40, where the retroreflective layer 40 is aretroreflective heat transfer film, the heat laminated retroreflectivelayer 40 of this embodiment strongly adheres to the second side 37 ofthe substrate 30 and to the surface 55 of the backing sheet 50 withinthe openings 39 of the substrate 30. That the method of the inventionmay employ existing heat laminating equipment such as that which isdetailed above provides that the invention is cost efficient andeconomical to adopt.

Furthermore, after the heat laminated retroreflective layer 40 is heatlaminated so as to adhere to the second side 37 of the substrate and tothe surface 55 of the backing sheet 50 within the openings 39 of thesubstrate 30 the method may include the additional step of cooling theheat laminated retroreflective layer 40 before the step of removing thebacking 50. This ensures that the heat laminated retroreflective layer40 has sufficiently cured to both the second side 37 of the substrateand to the surface 55 of the backing sheet 50 within the openings 39 ofthe substrate 30 such that when the backing 50 is removed the portions45 of the retroreflective layer 40 adhered to the backing 50 within theopenings 39 of the substrate 30 are effectively stripped away from theretroreflective layer 40 such that a smooth edge, and strong adherence,is obtained between the retroreflective layer 40 and the substrate 30 atthe edge of the openings 39.

In embodiments of the invention where the heat laminating machine 110 orthe heat press is employed, the predetermined temperature employed andthe predetermined time of engagement with the sandwiched substrate 30,backing 50 and retroreflective layer 40 may vary depending on variousfactors such as the characteristics of the substrate 30, backing 50 andretroreflective layer 40 employed in the method. Various temperature andtime parameters other than those expressly defined herein maynonetheless be suitable for use in embodiments of the invention wherethey provide adherence of the retroreflective layer 40 to the secondside 37 of the substrate 30 and to the surface 55 of the backing sheet50 within the openings 39 of the substrate 30 and as such may beconsidered as falling within the scope of embodiments of the invention.

The step in the method of removing the backing 50 is depicted in FIG. 3where it can be seen the backing 50 is removed by peeling the surface 55of the backing 50 away from the first side 35 of the substrate 30. Thisstrips away from the retroreflective layer 40 the portions 35 of theretroreflective layer 40 that are adhered to the surface 55 of thebacking 50 through the openings 39 of the substrate 30. The peeled awaybacking 50 having the portions 35 of the retroreflective layer 40adhered thereto are particularly shown in FIG. 5. The result of thisfinal step of the method is that it provides the perforatedretroreflective trim 20 shown in perspective view in FIG. 4 and in planview in FIG. 6.

FIG. 8 illustrates a preferred means of carrying out the step in themethod of removing the backing 50. After the substrate 30, the backing50 and the retroreflective layer 40 are respectively fed into thelaminating machine 110 of FIG. 7 where the retroreflective layer 40which is adhered to the second side 37 of the substrate 30 and to thesurface 55 of the backing sheet 50 within the openings 39 of thesubstrate 30 the retroreflective layer 40, the substrate 30 and thebacking sheet 50 are fed out of the laminating machine 110. The backing50, having adhered thereto the portions 45 of the retroreflective layer40, diverges from the substrate 30 and the retroreflective layer 40 andfeeds onto a roll 160 while the substrate 30 and the retroreflectivelayer 40, which at this stage of the method form the perforatedretroreflective trim 20, similarly feed onto a roll 150. Accordingly,this embodiment of the invention provides for continuous production ofthe perforated retroreflective trim 20 into a roll 150 which may beconveniently and efficiently stored, packaged and transported. Inanother form, the present invention may include a further step or stepsafter the step of removing the backing 50 such as providing furtherlayers and/or coatings. Such layers and/or coatings may include:providing protective layers and/or coatings for providing the perforatedretroreflective trim 20 with further resistance to abrasion and wear andtear; providing an adhesive layer for providing a perforatedretroreflective trim 20 in a form that is capable of being adhered to asurface or object; and providing a porous lining in face to face contactwith the first side of the substrate 30 of the perforatedretroreflective trim 20.

The above embodiments of the method of the invention enable: continuousformation of the perforated retroreflective trim 20 by enablingcontinuous provision of the substrate 30, the backing 50 andretroreflective layer 40; continuous adhering of the retroreflectivelayer 40 to the second side 37 of the substrate 30 and to the surface 55of the backing 50 within the openings 39 of the substrate 30 so thatportions 45 of the retroreflective layer 40 are continuously adhered tothe backing 50 within the openings 39 in the substrate 30; andcontinuous removal of the backing 50 from the first side 35 of thesubstrate 30 to continuously strip away from the retroreflective layer40 the portions 45 of the retroreflective layer 40 adhered to thebacking 50 within the openings 39 in the substrate 30 so as tocontinuously provide the perforated retroreflective trim 20.

In a preferred form of the method, after the step of removing thebacking 50 the method further includes heating or cooking theretroreflective layer 40. Preferably, the retroreflective layer 40 andsubstrate 30 are heated or cooked in a heat press set to a predeterminedtemperature and for a predetermined time. Preferably, the temperature is160° C. and the period of time is 25 seconds.

EXAMPLE

Reflective trim material was produced by employing the method of theinvention which involved providing a 58 millimetre polyester meshsubstrate, providing a PVC backing sheet on the first side of thesubstrate, providing a 50 millimetre retroreflective heat transfer filmon the second side of the substrate, placing the sandwich of thesubstrate, backing and retroreflective heat transfer film in a heatpress set to a temperature of 110° heating the sandwich for 15 seconds.The sandwich was removed and then allowed to cool. After cooling, thebacking was removed and the portions of the retroreflective layeradhered to the backing within the openings of the substrate werestripped away to provide the perforated retroreflective trim. Theperforated retroreflective trim was then cooked in the heat press set toa temperature of 160° for 25 seconds.

While the above detailed description of the invention details variouspreferred and envisaged embodiments of the invention it is to beappreciated that there may be other embodiments that incorporate theprinciples and/or spirit of the invention that have not been describedeither because they are not preferred or have not been envisaged andthat such embodiments ought to be considered to be within the scope ofthe invention disclosed herein.

1-22. (canceled)
 23. A perforated retroreflective composite sheetincluding: a substrate having opposite first and second sides and a filmof retroreflective material adhered to one side of the substrate, thesubstrate being preformed with a plurality of openings extendingtherethrough between the first and second sides and the film ofretroreflective material having removed portions at the openings in thesubstrate to form the perforated retroreflective composite sheet. 24.The perforated retroreflective composite sheet of claim 23, wherein thefilm of retroreflective material is adhered to the substrate aroundedges of the preformed openings and through the preformed openingsbetween the first and second sides of the substrate.
 25. The perforatedretroreflective composite sheet of claim 23, wherein the film ofretroreflective material is formed with smooth edges around thepreformed openings in the substrate.
 26. The perforated retroreflectivecomposite sheet of claim 23, wherein the retroreflective film is aretroreflective heat transfer film that is heat laminated to thesubstrate.
 27. The perforated retroreflective composite sheet of claim23, wherein openings are formed in the retroreflective film by havingportions of the retroreflective film stripped away after theretroreflective film is adhered to the substrate.
 28. The perforatedretroreflective composite sheet of claim 23, wherein the retroreflectivefilm around the openings in the substrate has melted or softened andbeen partially drawn through and into the openings in the substrate. 29.The perforated retroreflective composite sheet of claim 23, furtherincluding a coating layer formed over the film of retroreflectivematerial.
 30. The perforated retroreflective composite sheet of claim23, wherein the substrate is preformed with a plurality of rows andcolumns of the openings.
 31. The perforated retroreflective compositesheet of claim 23, wherein the substrate is a woven material.
 32. Theperforated retroreflective composite sheet of claim 23, wherein thesubstrate is a polyester mesh.
 33. A perforated retroreflective sheetincluding: a substrate in the form of a sheet of flexible materialhaving opposite first and second sides and being preformed with aplurality of openings extending therethrough between the first andsecond sides; and a film of retroreflective material adhered to one sideof the substrate, wherein portions of the film of retroreflectivematerial have been removed from within the openings in the substrate toform the perforated retroreflective sheet.
 34. A perforatedretroreflective sheet produced by a process including the steps of:providing a substrate having first and second sides and a plurality ofopenings extending between the sides; adhering a continuousretroreflective film to the second side of the substrate; and removingportions of the retroreflective film located within the openings of thesubstrate to provide the perforated retroreflective sheet.
 35. Theperforated retroreflective sheet of claim 34, wherein the process bywhich the perforated retroreflective sheet is produced further includesthe step of providing a backing on the first side of the substratebefore the step of adhering the continuous retroreflective film to thesecond side of the substrate such that the retroreflective film adheresto the second side of the substrate and to the backing within theopenings of the substrate so that portions of the retroreflective filmare adhered to the backing through the openings in the substrate. 36.The perforated retroreflective sheet of claim 35, wherein in the processby which the perforated retroreflective sheet is produced the step ofremoving portions of the retroreflective film located within theopenings of the substrate includes removing the backing from the firstside of the substrate to remove from the retroreflective film theportions of the retroreflective film adhered to the backing through theopenings in the substrate.
 37. The perforated retroreflective sheet ofclaim 36, wherein in the process by which the perforated retroreflectivesheet is produced the step of removing the backing includes peeling awaythe backing from the first side of the substrate to pull out theportions of the retroreflective film adhered to the backing through theopenings of the substrate to provide the perforated retroreflectivesheet.
 38. A garment including the perforated retroreflective compositesheet of claim
 23. 39. A garment including the perforatedretroreflective sheet of claim
 33. 40. A garment including theperforated retroreflective sheet of claim 34.